Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite

K. Rajkumar; M. Rajesh; K. Ramraji; P. Sabarinathan; A. Gnanavelbabu

doi:10.1007/978-981-15-4745-4_5

Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite

K. Rajkumar^*
, M. Rajesh
, K. Ramraji
, P. Sabarinathan
, A. Gnanavelbabu

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

3 Scopus citations

Abstract

A hard to machining characteristics of ceramic reinforced aluminum composite requires unconventional machining methods. Wire electrochemical machining (WECM) is one of the superior machining processes that produced a smoother and brighter surface with complex profile. In this investigation, optimization of process parameters is mainly focused for slit profile cutting on the aluminum 6061/TiB₂ composite by a WECM method. Liquid metallurgy route is employed to fabricate the composite with varied TiB₂ weight percentages (5 and 15%). The parameters of wire electrochemical cutting process are applied voltage (10–14 V), electrolyte flow rate (2–8 l/min), and electrolyte concentration (12–18%). These were optimized for achieving optimal material removal rate and surface roughness. The optimization of process parameters was carried out based on the response surface methodology. Electrolyte flow rate significantly increases MRR, surface roughness, and slit width. When considering the optimal MRR and slit width condition, the experiment results reveal a better surface finish at low-level electrolyte concentration. Inter-electrode voltage increases the strength of electrochemical ionization resulting in higher MRR, and on the other hand, it is considerably affected surface roughness.

Original language	English
Title of host publication	Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019
Editors	S. Vijayan, Nachiappan Subramanian, K. Sankaranarayanasamy
Publisher	Springer
Pages	39-50
Number of pages	12
ISBN (Print)	9789811547447
DOIs	https://doi.org/10.1007/978-981-15-4745-4_5
State	Published - 2021
Externally published	Yes
Event	2nd International Conference on Mechanical Engineering Design, ICMechD 2019 - Chennai, India Duration: 25 Apr 2019 → 26 Apr 2019

Publication series

Name	Lecture Notes in Mechanical Engineering
ISSN (Print)	2195-4356
ISSN (Electronic)	2195-4364

Conference

Conference	2nd International Conference on Mechanical Engineering Design, ICMechD 2019
Country/Territory	India
City	Chennai
Period	25/04/19 → 26/04/19

Bibliographical note

Publisher Copyright:
© 2021, Springer Nature Singapore Pte Ltd.

Keywords

Composite machining
Electrolyte
Surface roughness
TiB
Wire electrochemical machining

ASJC Scopus subject areas

Automotive Engineering
Aerospace Engineering
Mechanical Engineering
Fluid Flow and Transfer Processes

Access to Document

10.1007/978-981-15-4745-4_5

Cite this

Rajkumar, K., Rajesh, M., Ramraji, K., Sabarinathan, P., & Gnanavelbabu, A. (2021). Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite. In S. Vijayan, N. Subramanian, & K. Sankaranarayanasamy (Eds.), Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019 (pp. 39-50). (Lecture Notes in Mechanical Engineering). Springer. https://doi.org/10.1007/978-981-15-4745-4_5

Rajkumar, K. ; Rajesh, M. ; Ramraji, K. et al. / Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite. Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019. editor / S. Vijayan ; Nachiappan Subramanian ; K. Sankaranarayanasamy. Springer, 2021. pp. 39-50 (Lecture Notes in Mechanical Engineering).

@inproceedings{83c6f1cf0cfd4e4a9492610fab29c420,

title = "Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite",

abstract = "A hard to machining characteristics of ceramic reinforced aluminum composite requires unconventional machining methods. Wire electrochemical machining (WECM) is one of the superior machining processes that produced a smoother and brighter surface with complex profile. In this investigation, optimization of process parameters is mainly focused for slit profile cutting on the aluminum 6061/TiB2 composite by a WECM method. Liquid metallurgy route is employed to fabricate the composite with varied TiB2 weight percentages (5 and 15\%). The parameters of wire electrochemical cutting process are applied voltage (10–14 V), electrolyte flow rate (2–8 l/min), and electrolyte concentration (12–18\%). These were optimized for achieving optimal material removal rate and surface roughness. The optimization of process parameters was carried out based on the response surface methodology. Electrolyte flow rate significantly increases MRR, surface roughness, and slit width. When considering the optimal MRR and slit width condition, the experiment results reveal a better surface finish at low-level electrolyte concentration. Inter-electrode voltage increases the strength of electrochemical ionization resulting in higher MRR, and on the other hand, it is considerably affected surface roughness.",

keywords = "Composite machining, Electrolyte, Surface roughness, TiB, Wire electrochemical machining",

author = "K. Rajkumar and M. Rajesh and K. Ramraji and P. Sabarinathan and A. Gnanavelbabu",

note = "Publisher Copyright: {\textcopyright} 2021, Springer Nature Singapore Pte Ltd.; 2nd International Conference on Mechanical Engineering Design, ICMechD 2019 ; Conference date: 25-04-2019 Through 26-04-2019",

year = "2021",

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Rajkumar, K, Rajesh, M, Ramraji, K, Sabarinathan, P & Gnanavelbabu, A 2021, Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite. in S Vijayan, N Subramanian & K Sankaranarayanasamy (eds), Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019. Lecture Notes in Mechanical Engineering, Springer, pp. 39-50, 2nd International Conference on Mechanical Engineering Design, ICMechD 2019, Chennai, India, 25/04/19. https://doi.org/10.1007/978-981-15-4745-4_5

Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite. / Rajkumar, K.; Rajesh, M.; Ramraji, K. et al.
Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019. ed. / S. Vijayan; Nachiappan Subramanian; K. Sankaranarayanasamy. Springer, 2021. p. 39-50 (Lecture Notes in Mechanical Engineering).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite

AU - Rajkumar, K.

AU - Rajesh, M.

AU - Ramraji, K.

AU - Sabarinathan, P.

AU - Gnanavelbabu, A.

PY - 2021

Y1 - 2021

N2 - A hard to machining characteristics of ceramic reinforced aluminum composite requires unconventional machining methods. Wire electrochemical machining (WECM) is one of the superior machining processes that produced a smoother and brighter surface with complex profile. In this investigation, optimization of process parameters is mainly focused for slit profile cutting on the aluminum 6061/TiB2 composite by a WECM method. Liquid metallurgy route is employed to fabricate the composite with varied TiB2 weight percentages (5 and 15%). The parameters of wire electrochemical cutting process are applied voltage (10–14 V), electrolyte flow rate (2–8 l/min), and electrolyte concentration (12–18%). These were optimized for achieving optimal material removal rate and surface roughness. The optimization of process parameters was carried out based on the response surface methodology. Electrolyte flow rate significantly increases MRR, surface roughness, and slit width. When considering the optimal MRR and slit width condition, the experiment results reveal a better surface finish at low-level electrolyte concentration. Inter-electrode voltage increases the strength of electrochemical ionization resulting in higher MRR, and on the other hand, it is considerably affected surface roughness.

AB - A hard to machining characteristics of ceramic reinforced aluminum composite requires unconventional machining methods. Wire electrochemical machining (WECM) is one of the superior machining processes that produced a smoother and brighter surface with complex profile. In this investigation, optimization of process parameters is mainly focused for slit profile cutting on the aluminum 6061/TiB2 composite by a WECM method. Liquid metallurgy route is employed to fabricate the composite with varied TiB2 weight percentages (5 and 15%). The parameters of wire electrochemical cutting process are applied voltage (10–14 V), electrolyte flow rate (2–8 l/min), and electrolyte concentration (12–18%). These were optimized for achieving optimal material removal rate and surface roughness. The optimization of process parameters was carried out based on the response surface methodology. Electrolyte flow rate significantly increases MRR, surface roughness, and slit width. When considering the optimal MRR and slit width condition, the experiment results reveal a better surface finish at low-level electrolyte concentration. Inter-electrode voltage increases the strength of electrochemical ionization resulting in higher MRR, and on the other hand, it is considerably affected surface roughness.

KW - Composite machining

KW - Electrolyte

KW - Surface roughness

KW - TiB

KW - Wire electrochemical machining

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U2 - 10.1007/978-981-15-4745-4_5

DO - 10.1007/978-981-15-4745-4_5

M3 - Conference contribution

AN - SCOPUS:85090518528

SN - 9789811547447

T3 - Lecture Notes in Mechanical Engineering

SP - 39

EP - 50

BT - Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019

A2 - Vijayan, S.

A2 - Subramanian, Nachiappan

A2 - Sankaranarayanasamy, K.

PB - Springer

T2 - 2nd International Conference on Mechanical Engineering Design, ICMechD 2019

Y2 - 25 April 2019 through 26 April 2019

ER -

Rajkumar K, Rajesh M, Ramraji K, Sabarinathan P, Gnanavelbabu A. Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite. In Vijayan S, Subramanian N, Sankaranarayanasamy K, editors, Trends in Manufacturing and Engineering Management - Select Proceedings of ICMechD 2019. Springer. 2021. p. 39-50. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-981-15-4745-4_5

Electrolyte and Machining Parameters Optimization of Wire Electrochemical Cutting of Aluminum/Titanium Diboride Composite

Abstract

Publication series

Conference

Bibliographical note

Keywords

ASJC Scopus subject areas

Access to Document

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Cite this